Heat proof mat

ABSTRACT

A flexible heat resistant mat for use with a heated hair styling device, the mat being made of a fibrous material of which the fibres are capable of withstanding a temperature in excess of 225° C., wherein air spaces between the fibres give the material a sufficiently low thermal conductivity to permit a styling device having a temperature in excess of 200° C. to be supported on the mat for more than at least 10 minutes while resting on a surface capable of withstanding a temperature of about 70° C. without damage to the surfaces.

This invention relates to hair styling products and more specifically to providing safe use of hair styling devices.

Hair styling devices rely on elements which heat the hair and style it according to the type of style required. This is facilitated by trapping the hair between the jaws of the tongs which are shaped to produce a desired style. The shape of the jaws often defines the name of the implement for example, hair straighteners or hair curlers, sometimes known as tongs. The common feature of all these devices is the heating element provided inside a mass of metal which makes up the jaws of the device.

In order for the device to work over a sustained period without temperature variations, such devices have a substantial thermal mass such that application of the tongs to the hair does not immediately cool. As a direct result of this, even when disconnected from their power source (mains, chemical or rechargeable battery) they remain dangerously hot for some period of time. With this in mind there is a need to ensure that during such periods of non use and when in use, the tongs can safely be left unattended. This is important as it is often the case that a user is distracted while getting ready to go out.

In order to meet with this demand, a first aspect of the present invention provides a flexible heat resistant mat for use with a heated hair styling device, the mat being made of a fibrous material of which the fibres are capable of withstanding a temperature in excess of 225° C., wherein air spaces between the fibres give the material a sufficiently low thermal conductivity to permit a styling device having a temperature in excess of 200° C. to be supported on the mat for more than at least 10 minutes while resting on a surface capable only of withstanding a temperature of about 70° C. without damage to the surface.

According to a second aspect of the present invention a heat resistant mat in combination with a heated hair styling device is provided, the mat being made of a fibrous material of which the fibres are capable of withstanding a temperature in excess of 225° C., wherein air spaces between the fibres give the material a sufficiently low thermal conductivity to permit a styling device having a temperature in excess of 200° C. to be supported on the mat for more than at least 10 minutes while resting on a surface capable only of withstanding a temperature of about 70° C. without damage to the surface.

According to a third aspect of the present invention, there is provided, a method of transporting a heated hair styling device comprising the steps of providing a heat resistant flexible mat and wrapping the hair styling device inside the mat when in transit.

It is an advantage of the preferred embodiment of the present invention that the mat is flexible as this enables it to function as both a protective mat and heat proof packaging should the hair styling device need to be stored whilst still hot.

It is further advantageous for the mat to be capable of displaying information to enable it to be used as a vehicle for advertising.

It is possible to fold the mat over to produce a pocket. The pocket may be tapered to facilitate easy insertion and retention of the hair styling device. Equally the mat may be folded over and secured to itself to form a bag or pouch for containing the hair styling device during transit.

A further possibility is to produce a mat having two fibrous layers which sandwich a metal foil later between them to increase the mats ability to reduce heat transfer across it.

The invention will now be described further by way of example and with reference to the accompanying drawings in which:

FIG. 1 shows a perspective view of an embodiment of the present invention in a packaged position,

FIG. 2 shows a perspective view of a second embodiment of the present invention including a pocket for receiving a hair styling device, and

FIG. 3 shows a perspective view of a third embodiment in which the heat proof mat is formed as a bag.

The mat is formed by a series of processes as follows. The raw material is a polyester fibre though polyester is not a limitation, as it may be substituted by an alternative polymeric substance having heat resistant properties.

It has been found that in order to achieve the specific requirements of weight, flexibility and feel while still meeting the requirements of heat resistance, that it is advantageous to use two polyesters mixed in a ratio of nine to one. The first having a denier of 7.0 having fibres when straightened, half being 60 mm long and the other half being 76 mm long. The second polyester having a denier of 3.3 and fibres of the same differing lengths in the same proportion.

These raw materials are fed into a hopper. The hopper then feeds the fibres into a card. A card is a machine in which carding may be carried out, this is a process normally used to de-entangle fibres prior to spinning in order to make cloth. The card contains wire-toothed brushes which break apart the matted raw material to align the fibres, in the process cleaning them and stretching them out in the same direction.

Out of the card comes a web of fibre via a conveyor. A second layer or web laid over the first web at 90 degrees. This is repeated approximately 14 times producing a 15 ply material. The 15 ply web is then transferred to a needle loom, where it is punctured repeatedly by multiple barbed needles. This serves to interlock the different fibres within the many layers to give the material its structure, while movement of the fibres allow it to remain flexible yet strong. The air trapped within the fibre also aids with insulation.

The resulting material sheet can be cut to the required size which may be determined by the size of the hair styling device, more commonly referred to as irons, with which it is intended to be used.

An advantage of a heat resistant mat constructed in such a way is that it is capable of being hand washed. This enables the mat to be used to clean the metal surfaces of the irons. This is helpful as grease tends to build up on these surfaces during repeated use. The construction of the mat is further useful in that the fibres of the polymer make for a slightly abrasive texture which helps wipe surfaces clean.

Turning to FIG. 1, the mat 10 can be seen in an intended use in which it wraps or packages the irons 12 during transport. In such situations, it is worthwhile to provide some means of securing the mat to the irons. This may be provided for in many ways. As a result of the mat 10 being flexible it may be rolled up around the irons 12 encasing it entirely. In order to secure the packaged irons in this position it is advantageous to provide a fastener 20 which may consist of a popper, button and loop or more preferably a Velcro_(rtm) strap, extending from the rolled mat.

Further ways of supporting the irons within the mat include forming a pocket 14 within the mat 10 as shown in FIG. 2. This is effected by folding the mat 10 back upon itself to some degree and stitching or bonding the edge of the mat to itself along a line parallel to the fold in the mat and along one of the abutting sides, these sides are illustrated in figure as dotted lines. This leaves the opposite side open allowing for the insertion of the irons when not in use or during transport. The pocket may of course be tapered, creating a wider opening 16 for easy insertion of the irons, yet still ensuring the irons 12 stay in place when fully inserted.

An alternative extension of this idea is to further fold over the mat 10 to form a bag as shown in FIG. 3. The folded mat may then be easily stitched or bonded along the edges (shown again as dotted lines) perpendicular to the fold to form an internal pocket for receiving the irons during transit while the surface of the bag still acts as a heat resistant mat for placing the irons on to during use. By folding the mat just short of halfway, a flap 18 is created which may be used to close the bag by means of a suitable fastener (not shown) if required.

In order to increase the heat resistance of the mat, it is also possible to provide a heat reflective foil similar to aluminium foil between the folded layers of the bag, this serves to further improve the mats insulation properties without significantly affecting weight or flexibility.

An advantage of the material used to make the mat 10, is that it is capable of being embroidered onto, thus allowing it to be decoratively finished so that it may be aesthetically pleasing, or potentially carry the logo or similar trademark representing the manufacturer of the irons.

With decoration in mind, the material is also further capable of having a design or pattern applied to it by means of dye sublimation. This is a printing process wherein a pattern or design, potentially of multiple coloured dyes is applied to a film which is placed above the mat. As the printing head passes over the film, it causes the dye to vapourise and permeate through the film onto the mat beneath where it solidifies permanently. This allows complex patterns and designs including operating instructions and warnings to be printed on the mat for convenient access when using the irons. 

1-32. (canceled)
 33. A flexible heat resistant mat for use with a heated hair styling device, the mat being made of a fibrous material of which the fibres are capable of withstanding a temperature in excess of 225° c, wherein air spaces between the fibres give the material a sufficiently low thermal conductivity to permit a styling device having a temperature in excess of 200° c to be supported on the mat for more than at least 10 minutes while resting on a surface capable only of withstanding a temperature of about 70° c without damage to the surface.
 34. A heat resistant mat as claimed in claim 33, wherein the mat is constructed to protect the surface upon which it rests from the hair styling device at a temperature of approximately 210° celsius for 30 minutes.
 35. A heat resistant mat as claimed in claim 33, wherein the mat is sufficiently flexible to wrap around the hair styling device so that it may protect it while in transit.
 36. A heat resistant mat as claimed in claim 33, wherein the mat is folded over and secured back to itself to form a bag for receiving the device therein.
 37. A heat resistant mat as claimed in claim 33, further comprising a hook and loop strap, stitched to the body of the mat so that it may be secured in a wrapped position when enveloping the hair styling device.
 38. A heat resistant mat as claimed in claim 33, wherein the mat is made from a mixture of separate sheets of fibres of polyester polymer.
 39. A heat resistant mat as claimed in claim 33, wherein the two polyesters have a denier of substantially 3.3 and 7 respectively.
 40. A heat resistant mat as claimed in claim 33, wherein the fibres are woven together by a series of puncturing needles that force fibres in separate sheets of the unmixed fibres to intertwine with one another, to form one sheet of interwoven fibres.
 41. A heat resistant mat as claimed in claim 33, wherein the material is such that it may be dye printed with information.
 42. A heat resistant mat as claimed in claim 41, wherein the printing is effected by means of dye sublimation.
 43. A heat resistant mat as claimed in claim 33, wherein the material is capable of being embroidered onto.
 44. A heat resistant mat as claimed in claim 33, wherein the mat is folded back and secured on itself to produce an integral pocket for receiving the hair styling device.
 45. A heat resistant mat as claimed in claim 44, wherein the pocket is tapered to facilitate easy insertion of the hair styling device.
 46. A heat resistant flexible mat as claimed in claim 33, wherein the mat comprises two layers of interwoven fibres having and a further flexible heat reflective metal foil sheet sandwiched therebetween.
 47. A heat resistant mat in combination with a heated hair styling device, the mat being made of a fibrous material of which the fibres are capable of withstanding a temperature in excess of 225° C., wherein air spaces between the fibres give the material a sufficiently low thermal conductivity to permit a styling device having a temperature in excess of 200° C. to be supported on the mat for more than at least 10 minutes while resting on a surface capable only of withstanding a temperature of about 70° C. without damage to the surface.
 48. A heat resistant mat in combination with a heated hair styling device as claimed in claim 47, wherein the mat is constructed to protect the surface upon which it rests from devices at a temperature of approximately 210° celsius for 30 minutes.
 49. A heat resistant mat and hair styling device as claimed in claim 47, wherein the mat is flexible in order to wrap around the hair styling device so that it may protect it while in transit.
 50. A heat resistant mat and hair styling device as claimed in claim 47, wherein the mat is folded back on itself to folded over and secured back to itself in order to form a bag for receiving the hair styling device.
 51. A heat resistant mat and hair styling device as claimed in claim 47, wherein the mat is made from a mixture of separate sheets of two types of polyester polymers.
 52. A heat resistant mat and hair styling device as claimed in claim 47, wherein the fibres of the two types of polymer have a denier of substantially 3.3 and 7.0 respectively.
 53. A heat resistant mat and hair styling device as claimed in claim 47, wherein the fibres are woven together by a series of puncturing needles that force fibres in the separate sheets of the unmixed fibres to intertwine with one another.
 54. A heat resistant mat and hair styling device as claimed in claim 47, wherein the mat is made of a material that may be printed with information.
 55. A heat resistant mat and hair styling device as claimed in claim 54, wherein the printing is effected by means of dye sublimation.
 56. A heat resistant mat and hair styling device as claimed in claim 47, wherein the material is capable of being embroidered onto.
 57. A heat resistant flexible mat and hair styling device as claimed in claim 47, wherein the mat is folded back and secured on itself to produce an integral pocket for receiving the hair styling device.
 58. A heat resistant flexible mat and hair styling device as claimed in claim 57, wherein the pocket is tapered to facilitate easy insertion of the hair styling device.
 59. A heat resistant flexible mat and hair styling device as claimed in claim 47, wherein the mat comprises two layers of interwoven fibres having a further flexible heat reflective metal foil sheet sandwiched therebetween.
 60. A method of packaging a heated hair styling device comprising the steps of providing a heat resistant flexible mat and wrapping the hair styling device inside the mat when in transit.
 61. A method as claimed in claim 60, wherein the mat is further capable of unfolding into a protective mat for supporting the hair styling device on a surface in order to reduce the increased temperature at the surface caused by heat emitted from the hair styling device.
 62. A method as claimed in claim 60, wherein the mat is in the form of a bag which is suitable for receiving the device inside it during transit. 